Plug-in Hybrid Gasoline-Electric Hybrid Synergy Drive ZVW35 Series Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius Plug-in gasoline-electric hybrid vehicles. Prius Plug-in hybrid dismantling procedures are similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Prius Plug-in hybrid, as they may not be familiar to dismantlers. High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter. All other conventional automotive electrical devices such as the headlights, radio, and gauges are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the Prius Plug-in hybrid to help ensure the high voltage, approximately 346*1 or 207.2*2 Volt, Lithium-ion (Li-ion) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident. The Li-ion HV battery pack contains sealed batteries that are similar to rechargeable batteries used in some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte does leak, it can be easily neutralized with a dilute boric acid solution or vinegar. High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis of the vehicle. *1: 2010 Model *2: 2012 Model Additional topics contained in the guide include: • Toyota Prius Plug-in hybrid identification. • Major hybrid component locations and descriptions. By following the information in this guide, dismantlers will be able to handle Prius Plug-in hybrid-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile. ii The following indicates the key identification points for each model. Make sure to identify the target vehicle using this and refer to the corresponding rescue methods. Key Identification Points: 2010 Model Charge Inlet Door 2012 Model Charge Inlet Door Charge inlet door 2010 Model 2012 Model Exterior Rear and Left Side View 2010 Model 2012 Model Exterior Front and Left Side View © 2011 Toyota Motor Corporation All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. iii Table of Contents About the Prius Plug-in hybrid (2010 Model)............................................................................................1 Prius Plug-in hybrid Identification (2010 Model)......................................................................................2 Exterior .........................................................................................................................................................3 Interior...........................................................................................................................................................4 Engine Compartment ....................................................................................................................................5 Hybrid Component Locations & Descriptions (2010 Model) ...................................................................6 Specifications................................................................................................................................................7 Hybrid Synergy Drive Operation (2010 Model) ........................................................................................8 Vehicle Operation..........................................................................................................................................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model) ................................................9 HV Battery Pack............................................................................................................................................9 Components Powered by the HV Battery Pack.............................................................................................9 HV Battery Pack Recycling .........................................................................................................................10 Auxiliary Battery..........................................................................................................................................10 High Voltage Safety (2010 Model)............................................................................................................. 11 High Voltage Safety System........................................................................................................................ 11 Service Plug Grip ........................................................................................................................................12 Precaution to be observed when dismantling the vehicle (2010 Model).................................................13 Necessary Items .........................................................................................................................................13 Spills (2010 Model) .....................................................................................................................................14 Dismantling the vehicle (2010 Model).......................................................................................................15 Removal of HV battery (2010 Model).......................................................................................................19 HV Battery Caution Label (2010 Model) .................................................................................................35 About the Prius Plug-in hybrid (2012 Model)..........................................................................................36 Prius Plug-in hybrid Identification (2012 Model)....................................................................................37 Exterior .......................................................................................................................................................38 Interior.........................................................................................................................................................39 Engine Compartment ..................................................................................................................................40 Hybrid Component Locations & Descriptions (2012 Model) .................................................................41 Specifications..............................................................................................................................................42 Hybrid Synergy Drive Operation (2012 Model) ......................................................................................43 Vehicle Operation........................................................................................................................................43 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2012 Model) ..............................................44 HV Battery Pack..........................................................................................................................................44 Components Powered by the HV Battery Pack...........................................................................................44 HV Battery Pack Recycling .........................................................................................................................45 Auxiliary Battery..........................................................................................................................................45 iv High Voltage Safety (2012 Model).............................................................................................................46 High Voltage Safety System........................................................................................................................46 Service Plug Grip ........................................................................................................................................47 Precaution to be observed when dismantling the vehicle (2012 Model).................................................48 Necessary Items .........................................................................................................................................48 Spills (2012 Model) .....................................................................................................................................49 Dismantling the vehicle (2012 Model).......................................................................................................50 Removal of HV battery (2012 Model).......................................................................................................55 HV Battery Caution Label (2012 Model) .................................................................................................69 v About the Prius Plug-in hybrid (2010 Model) The Prius Plug-in hybrid contains a gasoline engine, an electric motor, and a newly developed large capacity Li-ion battery. It is the first Toyota hybrid that allows the HV battery to be plugged-in and charged by an external power source. Two power sources are stored on board the vehicle: 1. Gasoline stored in the fuel tank for the gasoline engine.